EP2964888B1 - Verfahren zur herstellung einer keramikmatrixverbundschaufel für einen gasturbinenmotor - Google Patents

Verfahren zur herstellung einer keramikmatrixverbundschaufel für einen gasturbinenmotor Download PDF

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Publication number
EP2964888B1
EP2964888B1 EP13870404.4A EP13870404A EP2964888B1 EP 2964888 B1 EP2964888 B1 EP 2964888B1 EP 13870404 A EP13870404 A EP 13870404A EP 2964888 B1 EP2964888 B1 EP 2964888B1
Authority
EP
European Patent Office
Prior art keywords
airfoil
slots
preform
cooling channel
cmc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13870404.4A
Other languages
English (en)
French (fr)
Other versions
EP2964888A2 (de
Inventor
Ted J. Freeman
Richard C. Uskert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce North American Technologies Inc
Original Assignee
Rolls Royce North American Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce North American Technologies Inc filed Critical Rolls Royce North American Technologies Inc
Publication of EP2964888A2 publication Critical patent/EP2964888A2/de
Application granted granted Critical
Publication of EP2964888B1 publication Critical patent/EP2964888B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/186—Film cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187—Convection cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/10—Manufacture by removing material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/50—Building or constructing in particular ways
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/10—Stators
    • F05D2240/12—Fluid guiding means, e.g. vanes
    • F05D2240/122—Fluid guiding means, e.g. vanes related to the trailing edge of a stator vane
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/304—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the trailing edge of a rotor blade
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F05D2300/6033—Ceramic matrix composites [CMC]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade

Definitions

  • the present application relates to methods for making gas turbine engine ceramic matrix composite airfoils, and more particularly, but not exclusively, to methods for incorporating breathing passages in gas turbine engine ceramic matrix composite airfoils.
  • the present disclosure may comprise one or more of the following features and combinations thereof.
  • An illustrative method of fabricating an airfoil preform comprises the steps of fabricating an airfoil preform having a slotted forward end and a continuous trailing end; coupling the slotted forward end of the airfoil preform to an airfoil core insert; applying a ceramic matrix composite covering to cover the slots of the airfoil preform; and removing the continuous trailing end of the airfoil preform to expose the slots.
  • an illustrative method comprises the steps of forming a ceramic material airfoil core having a spanwise extending delivery member at a leading end, a spanwise extending sacrificial member at a trailing end, and a plurality of channel-defining members extending chordwise between the spanwise extending delivery member and the spanwise extending sacrificial member, wherein adjacent ones of the plurality of channel-defining members define therebetween cooling channels in the ceramic material airfoil core; applying a ceramic fiber cover to the ceramic material airfoil core to encapsulate the cooling channels; and removing the spanwise extending sacrificial member to expose the cooling channels.
  • the method comprises the steps of providing a cooling passage preform having a spanwise extending trailing end portion and a plurality of flow dividing members projecting from the spanwise extending trailing end portion that define cooling passages therebetween; coupling a cooling delivery core to a forward end of the cooling passage preform to close a forward end of the cooling passages; covering the cooling passages with a ceramic matrix material; and trimming the spanwise extending trailing end portion of the cooling passage preform to expose the cooling passages.
  • an illustrative gas turbine engine airfoil made according by any of the illustrative methods disclosed herein is also disclosed.
  • an illustrative gas turbine engine airfoil comprises an airfoil preform having a continuous trailing end and a forward end, wherein the forward end includes slots; an airfoil core insert, the airfoil preform and the slotted forward end of the airfoil core insert being coupled together; and a ceramic matrix composite covering the slots.
  • the CMC airfoil can comprise any type of gas turbine engine airfoil, for example, a gas turbine engine blade or a gas turbine engine vane.
  • various techniques can be used to form the cooling passages in the CMC airfoil, including for example the incorporation of various shapes, sizes, and curvature, in the CMC airfoil.
  • FIGS. 1A and 1B show two non-limiting examples of cooling channel preforms 10A, 10B according to an embodiment.
  • the reference numeral 10 refers to both the cooling channel preform 10A and the cooling channel preform 10B.
  • the cooling channel preform 10 can be made of any suitable composite material, for example, a monolithic ceramic or a single ply or multiple ply rigidized ceramic matrix composite (CMC).
  • the cooling channel preform 10 has a forward end 14, a trailing end 16, a lower surface 22, and an upper surface 24.
  • these descriptors correspond respectively to the forward end, the trailing end, the pressure side (lower surface), and the suction side (upper surface) of a finished CMC airfoil 80 such as shown in FIG. 5 that the cooling channel preform 10 and other airfoil components described herein ultimately form.
  • the forward end 14 has a forward edge 30 and the trailing end 16 has a trailing edge 32.
  • the manner by which the cooling channel preform 10 is manufactured can be based on any number of factors. In one form, the cooling channel preform 10 is manufactured based on the particular temperature and pressure requirements of the finished CMC airfoil 80 in the gas turbine engine. Thus, the cooling channel preform 10 can be manufactured based on the mean camber line of the finished CMC airfoil 80, that is the line extending from the forward edge to the trailing edge of the finished CMA airfoil 80.
  • the cooling channel preform 10 includes a plurality of flow separator members 36 that extend perpendicularly from a continuous spanwise extending member 40 at the trailing end 16 of the cooling channel preform 10.
  • the flow separator members 36 are spaced apart in the spanwise direction by gaps, that is slots 42, therebetween that extend through the thickness of the cooling channel preform 10, that is from the upper surface 24 to the lower surface 22 of the cooling channel preform 10.
  • the flow separator members 36 and associated slots 42 are formed in the fabrication process of the ceramic matrix composite (CMC) that forms the cooling channel preform 10.
  • CMC ceramic matrix composite
  • the slots 42 are formed by one or more suitable composite material removal techniques, for example, grinding, machining, electro-chemical erosion, and/or laser cutting; the technique leaving as a result the flow separator members 36 and the continuous spanwise extending member 40.
  • the as-shown continuous spanwise extending member 40 has a linear trailing edge profile.
  • the continuous spanwise extending member 40 can have a curved or otherwise nonlinear trailing edge profile, as will be appreciated.
  • the flow separator members 36 form slots 42 having a straight or linear configuration
  • the flow separator members 36 form slots 42 having a linear configuration and a forward end taper 46.
  • the slots 42 of the cooling channel preform 10 have the same size and are equally spaced apart in the spanwise direction, and each has a substantially uniform width.
  • the slots 42 are open at the forward end 14, and closed at the trailing end 16 by way of the continuous spanwise extending member 40.
  • the slots 42 have a length in the chordwise direction that is greater than a length from a location at which the cooling channel preform 10 engages a below-described delivery member 50 to the trailing edge 88 of the finished CMC airfoil 80.
  • the cooling channel preform 10 is not limited to the configuration shown in FIGS. 1A and 1B , and other embodiments are contemplated.
  • the flow separator members 36 of the cooling channel preform 10 can form a single slot 42 rather than multiple slots 42.
  • the flow separator members 36 can form slots 42 that do not extend through the thickness of the cooling channel medium 10, but rather through only a portion of the thickness, so that the slots 42 are bordered by for example a lower wall between flow separator members 36.
  • the flow separator members 36 can form slots 42 having a shape that is non-linear, for example, a curved or sinusoidal shape, or an irregular shape.
  • one or more slots 42 can have a size that is different from that of one or more other slots 42.
  • the slots 42 can be unequally spaced apart in the spanwise direction.
  • one or more slots 42 can be equally spaced apart and one or more slots 42 can be unequally spaced apart.
  • one or more slots 42 can have a non-uniform width, that is a width that changes from the forward end 14 to the trailing end 16 of the cooling channel preform 10.
  • one or more slots 42 can be closed at the forward end 14 by way of a forward end continuous spanwise extending member.
  • one or more slots 42 can branch off from another slot 42.
  • the cooling channel preform 10 is coupled to a delivery member 50.
  • the forward end 14 of the cooling channel preform 10 is configured to engage a trailing end 54 of the delivery member 50.
  • the forward end 14 of the cooling channel preform 10 is sealed against the trailing end 54 of the delivery member 50.
  • the delivery member 50 is formed based on the particular requirements of the finished CMC airfoil 80.
  • the delivery member 50 can comprise any suitable system that can deliver cooling fluid to the slots 42 of the finished CMC airfoil 80.
  • the delivery member 50 comprises a CMC foam material.
  • the delivery member 50 can comprise a removable core pin.
  • the delivery member 50 can be formed for example during a subsequent layup manufacturing process. Other forms are also contemplated, as will be appreciated. In one form, for example, the delivery member 50 can be configured and/or shaped so as to control one or more of the pressure, velocity and/or temperature of the cooling fluid entering the slots 42.
  • the delivery member 50 has a configuration and/or shape that can allow the receipt of the forward end 14 of the cooling channel preform 10 and/or that can seal against the forward end 14 of the cooling channel preform 10 in a flush manner.
  • the CMC foam material 50 is shaped to have a groove 56 in its trailing edge 58 that can receive the forward edge 30 of the cooling channel preform 10. As such, the forward edge 30 of the flow separator members 36 protrudes into and is thus captured in the trailing edge 58 of the delivery member 50.
  • the protrusion of the cooling channel preform 10 into the delivery member 50, or the flush sealing of the cooling channel preform 10 in abutting relation with the delivery member 50 can inhibit or prevent matrix material applied in a subsequent composite manufacturing process from inadvertently sealing or otherwise blocking the slots 42.
  • a ceramic matrix composite (CMC) cover 60 is applied to the delivery member 50 and the cooling channel preform 10.
  • the CMC cover 60 can comprise any suitable airfoil core, wrap plies, or matrix material, for example, fabric, tape, and/or ceramic fibers, and any suitable manufacturing process can be employed. In one form, for example, the material matrix is applied by a layup manufacturing process. Further, the CMC cover 60 can take any suitable shape and thickness, and can be applied in any suitable order and/or location that produces the desired CMC airfoil shape upon consolidation/solidification.
  • FIG. 3 shows one non-limiting example of a CMC cover 60 of airfoil core and wrap plies. In the FIG. 3 embodiment, the CMC cover 60 extends over the length or chordwise extent of the cooling channel preform 10 so as to at least encapsulate the slots 42.
  • the delivery member 50 comprises a CMC foam delivery member.
  • the delivery member 50 can comprise a cavity.
  • the delivery member 50 can comprise, in part, a CMC foam and, in part, a cavity.
  • the trailing end 70 of the consolidated product 74 is trimmed to length and shaped, exposing the slot cooling passages 42.
  • the trimming can be by any suitable manufacturing technique, such as by machining, cutting, etc.
  • FIG. 4 shows an example of a trimmed consolidated product 76. The trimming can be at any location along the chordwise dimension of the consolidated product 74 to expose the encapsulated slots 42. Shaping of the consolidated product 74 can be performed prior or subsequent to the trimming.
  • FIG. 5 shows an example of the finished CMC airfoil 80 in which the pressure side portion of the CMC cover 60 has been made see-through to show the underlying slots 42.
  • cooling fluid represented by arrows 82 passes through the CMC foam (or cavity or cavity insert) 50, enters the slot cooling passages 42, and exits the trailing edge 88 of the CMC airfoil 80, providing cooling to the CMC airfoil 80.
  • FIG. 6 shows a trailing edge 88 view of the CMC airfoil 80.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (6)

  1. Verfahren mit den Schritten:
    Herstellen einer Schaufelvorform mit einem geschlitzten vorderen Ende (14) und einem durchgehenden hinteren Ende (16);
    wobei in einem nächsten Schritt das vordere Ende (14) der Schaufelvorform an einen Kerneinsatz der Schaufel gekoppelt wird;
    Aufbringen einer Abdeckung aus keramischem Faserverbundwerkstoff direkt auf die Schlitze (42), um die Schlitze (42) der Schaufelvorform abzudecken; und
    Entfernen, nämlich Zuschneiden der Länge des durchgehenden hinteren Endes (16) des verfestigten Produktes aus der Schaufelvorform zur Freilegung der Schlitze (42).
  2. Verfahren gemäß Anspruch 1, bei welchem die Schaufelvorform eine monolithische Keramik aufweist.
  3. Verfahren gemäß Anspruch 1, bei welchem sich die Schlitze (42) im Wesentlichen senkrecht zu dem durchgehenden hinteren Ende (16) der Schaufelvorform erstrecken.
  4. Verfahren gemäß Anspruch 1, bei welchem sich die Schlitze (42) durch die Dicke der Schaufelvorform erstrecken.
  5. Verfahren gemäß Anspruch 1, bei welchem die Schlitze (42) ausgebildet werden, indem Material aus der Schaufelvorform abgetragen wird.
  6. Verfahren gemäß Anspruch 1, bei welchem die Kopplung den Schritt des Aufnehmens des geschlitzten vorderen Endes (14) der Schaufelvorform in einer Spannweitennut in dem hinteren Ende (16) des Schaufelkerneinsatzes umfasst.
EP13870404.4A 2013-03-04 2013-12-26 Verfahren zur herstellung einer keramikmatrixverbundschaufel für einen gasturbinenmotor Active EP2964888B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361772261P 2013-03-04 2013-03-04
PCT/US2013/077893 WO2014158277A2 (en) 2013-03-04 2013-12-26 Method for making gas turbine engine ceramic matrix composite airfoil

Publications (2)

Publication Number Publication Date
EP2964888A2 EP2964888A2 (de) 2016-01-13
EP2964888B1 true EP2964888B1 (de) 2019-04-03

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EP13870404.4A Active EP2964888B1 (de) 2013-03-04 2013-12-26 Verfahren zur herstellung einer keramikmatrixverbundschaufel für einen gasturbinenmotor

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US (1) US9683443B2 (de)
EP (1) EP2964888B1 (de)
CA (1) CA2897058A1 (de)
WO (1) WO2014158277A2 (de)

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US10309254B2 (en) * 2016-02-26 2019-06-04 General Electric Company Nozzle segment for a gas turbine engine with ribs defining radially spaced internal cooling channels
US10605095B2 (en) * 2016-05-11 2020-03-31 General Electric Company Ceramic matrix composite airfoil cooling
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US10767502B2 (en) 2016-12-23 2020-09-08 Rolls-Royce Corporation Composite turbine vane with three-dimensional fiber reinforcements
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WO2014158277A2 (en) 2014-10-02
CA2897058A1 (en) 2014-10-02
US9683443B2 (en) 2017-06-20
US20150004000A1 (en) 2015-01-01
EP2964888A2 (de) 2016-01-13
WO2014158277A3 (en) 2014-12-31

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